WP-P5-S1_19!8!15 General Specification of Main Laying Materials for Waterworks

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WP- P5/ S1

General Specification of Main

Laying Materials For

Waterworks

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Department

Department Document Type Document Type Document Document TitleTitle

WP Standard

WP Standard General Specification of MainGeneral Specification of Main

Laying Materials for Waterworks Laying Materials for Waterworks

Issue Approval Issue Approval Prepared

Prepared By By Approved Approved ByBy

Eng.

Eng. Osama Samaan Sleem FadayelOsama Samaan Sleem Fadayel Engineer (Material

Engineer (Material SpecificatioSpecifications)ns) Eng. Eid Auwid Khlaif Al-Idmat Eng. Eid Auwid Khlaif Al-Idmat

Engineer (Material

Engineer (Material SpecificatioSpecifications)ns) Eng. Ali Al_obaidly Eng. Ali Al_obaidly Head, Materials Standards &

Head, Materials Standards & SpecificationSpecifications Section s Section

Eng. Mohd Thani E.J. AL-Maadead Eng. Mohd Thani E.J. AL-Maadead

Manager, Water Planning Department Manager, Water Planning Department

Signature: Signature:

Issue

Issue No. No. Date Date Reason Reason for for re-issuing re-issuing StandardStandard 0.0

0.0 12/04/2015 12/04/2015 First First issue issue of of the the Standard.Standard. 1.0

1.0 19/8/2015 19/8/2015 Updated Updated & & modified modified the the Table Table of of ContentsContents 2.0 2.0 3.0 3.0 4.0 4.0 5.0 5.0 Key

Key Words Words :: Standard, Specification, materials, Manufacturer, Quality bodyStandard, Specification, materials, Manufacturer, Quality body certifier, ISO, BS, EN,

certifier, ISO, BS, EN, WRc , WRc , Ductile Iron Pipes, Ductile Iron Pipes, Fittings &Fittings &

Accessories, valves , Pumps, Water Meter, Copper, Polyethylene Accessories, valves , Pumps, Water Meter, Copper, Polyethylene

Pipes &

Pipes & Fittings Fittings and corrosion and corrosion protection materials protection materials ..

Review

Review Frequency Frequency :: Annually Annually

Document Control

signed

signed origin origin l l filed filed sep sep r r telytely Signature:Signature: signed signed origin origin l l filed filed sep sep r r telytely

Issue Record

When the document has been

When the document has been approved to publish on the approved to publish on the intranet intranet a copy of this Document Cona copy of this Document Controltrol page should be sent to the QA section wh

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Department

Department Document Type Document Type Document Document TitleTitle

WP Standard

WP Standard General Specification of MainGeneral Specification of Main

Laying Materials for Waterworks Laying Materials for Waterworks

Issue Approval Issue Approval Prepared

Prepared By By Approved Approved ByBy

Eng.

Eng. Osama Samaan Sleem FadayelOsama Samaan Sleem Fadayel Engineer (Material

Engineer (Material SpecificatioSpecifications)ns) Eng. Eid Auwid Khlaif Al-Idmat Eng. Eid Auwid Khlaif Al-Idmat

Engineer (Material

Engineer (Material SpecificatioSpecifications)ns) Eng. Ali Al_obaidly Eng. Ali Al_obaidly Head, Materials Standards &

Head, Materials Standards & SpecificationSpecifications Section s Section

Eng. Mohd Thani E.J. AL-Maadead Eng. Mohd Thani E.J. AL-Maadead

Manager, Water Planning Department Manager, Water Planning Department

Signature: Signature:

Issue

Issue No. No. Date Date Reason Reason for for re-issuing re-issuing StandardStandard 0.0

0.0 12/04/2015 12/04/2015 First First issue issue of of the the Standard.Standard. 1.0

1.0 19/8/2015 19/8/2015 Updated Updated & & modified modified the the Table Table of of ContentsContents 2.0 2.0 3.0 3.0 4.0 4.0 5.0 5.0 Key

Key Words Words :: Standard, Specification, materials, Manufacturer, Quality bodyStandard, Specification, materials, Manufacturer, Quality body certifier, ISO, BS, EN,

certifier, ISO, BS, EN, WRc , WRc , Ductile Iron Pipes, Ductile Iron Pipes, Fittings &Fittings &

Accessories, valves , Pumps, Water Meter, Copper, Polyethylene Accessories, valves , Pumps, Water Meter, Copper, Polyethylene

Pipes &

Pipes & Fittings Fittings and corrosion and corrosion protection materials protection materials ..

Review

Review Frequency Frequency :: Annually Annually

Document Control

signed

signed origin origin l l filed filed sep sep r r telytely Signature:Signature: signed signed origin origin l l filed filed sep sep r r telytely

Issue Record

When the document has been

When the document has been approved to publish on the approved to publish on the intranet intranet a copy of this Document Cona copy of this Document Controltrol page should be sent to the QA section wh

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Contents Page

Title

Title Page Page 11

Document

Document Control Control & & Issue Issue Record Record Page Page 22 Contents

Contents of of General General Specification Specification of of Main Main Laying Laying Materials Materials for for Waterworks Waterworks 33

Purpose 8

Scope 8

Responsibilities

Responsibilities & & Authorities Authorities 88 Abbreviations & Terminolo

Abbreviations & Terminologies gies 88

Section

Section - - 1 1 General General 99

1.1

1.1 Suitability Suitability of of MaterialsMaterials 99 1.2

1.2 Transport Transport & & storage storage of of materialsmaterials 1010 1.3

1.3 Manufacturer ‘sManufacturer ‘s CertificationCertification 1111 1.4 Standards

1.4 Standards 1111

1.5

1.5 Material Material Coating Coating & & Internal Internal ComponentsComponents 1111 1.6 Fasteners 1.6 Fasteners 1212 1.7 Inspection 1.7 Inspection 1212 1.8 Packing 1.8 Packing 1313 1.9

1.9 Technical Technical clarificationclarification 1313 1.10 Samples

1.10 Samples 1313

1.11

1.11 Alternative Alternative MaterialsMaterials 1313 Section - 2 Ductile Iron Pipes and Fittings

Section - 2 Ductile Iron Pipes and Fittings 1414 2.1 General

2.1 General 1414

2.2 Joints

2.2 Joints 1414

2.3

2.3 Length Length of of pipespipes 1414

2.4 Marking

2.4 Marking 1414

2.5

2.5 Certificate Certificate of of TestTest 1515 2.6

2.6 External External & & Internal Internal Coating Coating of of Ductile Ductile Iron Iron Pipes Pipes & & Fittings Fittings DuringDuring Manufactory

Manufactory 1515

2.7

2.7 Factory Factory Applied Applied Polyethylene Polyethylene External External CoatingCoating 1616 2.8

2.8 Protection Protection of of Above Above Ground Ground & & Inside Inside chambers chambers D.I. D.I. Pipes Pipes & & FittingsFittings 1616 2.9

2.9 special special protection protection of of D.I. D.I. Pipes Pipes & & FittingsFittings 1717 2.10

2.10 Pipe Pipe CuttingCutting 1717

2.11 Packing

2.11 Packing 1717

Section - 3 Slip-On

Section - 3 Slip-On Coupling and Flange Adaptors and Dismantling Joints andCoupling and Flange Adaptors and Dismantling Joints and Step Couplings

Step Couplings 1818

3.1 General

3.1 General 1818

3.2

3.2 Slip-on Slip-on couplingscouplings 1818 3.3

3.3 Mechanical Collar’sMechanical Collar’s 1818 3.4

3.4 Flange Flange adaptersadapters 1818

3.5

3.5 Dismantling Dismantling JointsJoints 1818 3.6

3.6 Step Step couplingscouplings 1818

3.7

3.7 External External And And Internal Internal Coating Coating of of Slip-on Slip-on Couplings, Couplings, Step Step Couplings,Couplings, Flange Adapters And Dismantling Joints During Manufacture

Flange Adapters And Dismantling Joints During Manufacture 1919 3.8 Fasteners

3.8 Fasteners 1919

3.9

3.9 Identification Identification Metal Metal StripStrip 1919 3.10 Packing

3.10 Packing 1919

Section - 4 Corrosion Protection of

Section - 4 Corrosion Protection of Ductile Iron Pipes, Fittings & Ductile Iron Pipes, Fittings & AccessoriesAccessories 2020 4.1

4.1 Pipe Pipe Wrapping Wrapping TapeTape 2020 4.2

4.2 Wrapping Wrapping ProcedureProcedure 2020

1. Purpose

This Standard provides “Materials Standards & Specifications Section’s Engineers” the specification of materials used for water works.

2 . S c o p e

This Standard is applicable to all materials used for waterworks.

3. Responsibilities & Authorities

Responsibilities and authority for ensuring that the steps in this guideline shall be carried out are specified at relevant steps in the guideline and include:

 Manager, Water Planning Department

 Head, Materials Standards & Specifications Section  Materials Standard Engineer.

 Materials Specification Engineer.

If the responsible personnel listed above are absent, these responsibilities shall be designated to the relevant staff.

4. Abbreviations & Terminology

KM : Qatar General Electricity and Water Corporation KAHRAMAA : Qatar General Electricity and Water Corporation

WP :Water Planning

MSS :Materials Standards & Specifications Section

GIS :Geographical Information System

NDS :Planning & Network Development Section

Term Description

BS British Standard- one of the international standard used in

General Specifications for main laying materials for waterworks

ISO

International Standards Organization - one of the international standards used in General Specifications for main laying

materials for waterworks.

WRC Water Research Council- international body who certifies the non-toxicity of material if contact with potable water.

Manufacturer A company whose business is manufacturing a certain product Material An item intended to be used in a certain construction works or

projects.

Specification

A detailed exact statement of particulars, especially a statement prescribing materials, dimensions and quality of work for something to be built, installed or manufactured.

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Section - 1

General

1.1 SUITABILITY OFMATERIALS

1.1.1 All materials in direct contact with potable water must have a health certificate issued by Worldwide Known Quality Body Certifier (See Appendix ‘IV’) in accordance with requirement of BS6920 “Suitability of Non-Metallic Products for use in direct contact with Water Intended for Human Consumption with regards to their effect on the quality of Water”.

1.1.2 All pipe-laying materials shall be suitable for use with the range of chemical characteristics of the water and complies with KAHRAMAA Water Quality Requirements & GCC Standards as detailed in Appendix ‘I’.

1.1.3 All materials shall be suitable for using and storing in the environmental conditions detailed in Appendix ‘II’ with minimum working water temperature at 50º C, unless otherwise specified, all works shall conform to PN16 standards and other standards noted elsewhere in this specification. 1.1.4 The Tenderer shall supply materials from any of the latest approved KAHRAMAA

manufacturers list and furnish to Water Network Planning Department for review and approval. 1.1.5 All the relevant Technical documents of the materials/manufacturers must be in Original OR

Notarized copy and shall be submitted from the Manufacturer for Technical Evaluation.

1.1.6 All materials shall be inspected and tested to ensure compliance with KAHRAMAA requirements and General Specifications for Main laying Materials. The testing shall be carried out according to relevant standards approved by Water Network Planning Department.

1.1.7 All The Engineer may test any materials before they leave the manu facturer’s premises or after delivery to the site.

1.1.8 The Engineer may reject any materials after delivery to the site should he consider them un-satisfactory, notwithstanding any preliminary test approval of the materials at the manufacturers premises.

1.1.9 The cost of all tests necessary to ensure compliance with the Project Documentation, shall be borne by the Contractor.

1.1.10 The number of samples to be tested at the local testing laboratory, must be not less than One Number of each diameter of the ordered materials, the cost of all tests necessary to ensure compliance with the Project Documentation, shall be borne by the Contractor.

1.1.11 The Local test certificates shall be issued by:-I. Manufacturer premises

II. Central Materials Laboratory.

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1.2 TRANSPORT& STORAGE OF MATERIALS

1.2.1 All materials handling, transporting and storing should comply with KAHRAMAA and manufacturer recommendation to avoid damages due to double handling.

1.2.2 During transport, extra care needed to avoid damaging the coating of the materials. Cleaning any foreign matter deposited on Materials during transport.

1.2.3 All materials to be stored are strictly in accordance with the KAHRAMAA requirements/Manufacturer storage recommendation at all times, all corrosion protection materials shall be stored under the shade and not to be exposed under

direct sunlight.

1.2.4 Upon materials delivery to the Contractor’s stores at site, the contractor should unpack, open all crates etc., and unload to areas as directed by the Store controller or KAHRAMAA Site Engineer. The contractor shall provide all timbers and packing, necessary for the correct stacking of pipes, fittings and other delivered

materials.

1.2.5 After inspection the contractor shall shift and stack the approved materials to areas as directed by store controller/KAHRAMAA Site Engineer.

1.2.6 All Coated materials such as (Epoxy, Polyurethane, and Risen) shall be handled with special care during loading, transportation and unloading to avoid accidental damage.

1.2.7 The Pipes may be stored in the open areas; however it shall be stacked off the ground on 150 x 100 mm timber skids to be provided by the Contractor. The stacking shall be done according to the manufacturer's recommendations.

1.2.8 Fittings, rubber gaskets, nuts, bolts etc. shall be withdrawn from storage and delivered to the site to suit the daily construction requirements.

1.2.9 All materials which are subject to deterioration by Ultraviolet Light such as Rubber gaskets, fixing materials, instruments, polyethylene sheeting etc. must be stored so that they are not exposed to direct sunlight.

1.2.10 Materials which are liable to deteriorate shall be used in the order of delivery.

1.2.11 The provision and correct usage of broad band slings is particularly important for the lowering of pipes into the trench. The Contractor shall take the utmost care to prevent any damage to the coating or sleeving during lowering-in, alignment, jointing and final removal of the lifting sling. In all cases an approved non metallic

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1.3 MANUFACTURER‘SCERTIFICATION

1.3.1 The Applicant must have a valid ISO 9001 Certificate issued by the granting certifier body holding BS EN ISO/IEC 17021:2011 certificates.

1.3.2 The applicant must have successful records of experiences for supplying of minimum 15 year in International market and 5 year minimum in regional / GCC market for prequalifying.

1.3.3 Provide the QA/QC plan.

1.3.4 Provide organization chart including personals Crucial Vita. 1.4 STANDARDS

1.4.1 The Tenderer shall follow the latest KAHRAMAA General Specifications of Main laying Materials for Waterworks.

1.4.2 In case of materials were not mentioned in this document, the Tenderer shall follow the latest edition of one of the following appropriate relevant standards such as BS, ISO, EN or DIN with all subsequent amendments up to the year of the materials order. Submit complete documents to Water Network Planning department for further evaluation.

1.5 MATERIALCOATING& INTERNALCOMPONENTS

1.5.1 All materials in direct contact with potable water must have a health certificate issued by Worldwide Known Quality Body Certifier (See Appendix IV) as per requirement of BS6920 "Suitability of Non-Metallic Products for use in contact with Water Intended for Human Consumption with regards to their effect on the quality of Water”

1.5.2 Coating shall be smooth and mirror finish without any air bubbles or pebbles, and the thicknesses shall as per the relevant specifications given below;

I. The minimum thickness is 300 micron Fusion bonded epoxy (Polymeric anticorrosion) coating as per WIS No. 4-52-01.

II. The minimum thickness is 300 micron Electrostatic ally applied epoxy coating.

III. The minimum thickness is 300 micron Fluidized bed epoxy coating.

1.5.3 The coating quality shall conform to the following tests as per the relevant specifications given below;

 Adhesion Test: Coating adhesion to metal shall not be less than 12N/mm² (BSI BS EN ISO 4624).

 Holiday Test: Coating porosity shall be “zero” on 3 kV DC tester.  Hardness: Intrinsic Rockwell hardness shall be between50 - 60.

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1.5.4 Impact resistance: For applying of impact energy of 5 NM on coating the cracks should not be develop, when tested by 3 kV DC tester.

1.6 FASTENERS

1.6.1 All Bolts, Nuts & Washers connected to Valves, Fire Hydrants, Couplings, Adaptors and Dismantling Joints shall be Mild steel with hot dipped zinc galvanized, with minimum thickness 70 micron.

1.6.2 All Bolts, Nuts & Washers connected to Valves, Fire Hydrants, Couplings,

Adaptors and Dismantling Joints shall be protect with putty and wrapping tape. 1.6.3 Saddle Strap fasteners should be Stainless Steel “A4”.

1.7 INSPECTION

1.7.1 Pre-Inspection Arrangement shall comply with the requirements as per the attached procedure. (See Appendix V).

1.7.2 KAHRAMAA reserves the right to inspect the materials in the factory.

1.7.3 The manufacturer shall allow access at all times during manufacturing and testing to the premises in which the material being manufactured.

1.7.4 Upon receipt of materials at the contractor's site store, materials to be inspected by Supervising Consultant of the subject project.

1.7.5 Upon KAHRAMAA Engineer receipt of the Materials Request for Inspection, he will visit the contractor store. If any damage on the Pipe’s / Fitting’s is observed and it can be repaired, it's the contractor's responsibility to perform the repair in accordance with the manufacturer's recommendations and the approval of KAHRAMAA - repair works should be carried under direct supervision of the manufacturer.

1.7.6 KAHRAMAA reserves the right to reject the supplied material during final inspection or at later date, if found not as per the General Specification and will have the right to put the Manufacturer under “ ON HOLD “ or “ BLACK LISTED “ until further action.

1.7.7 The non-repairable rejected materials, which were not complying with KM Specifications during inspection and marked by the Engineer (rejected), must be removed by the Contractor and to be shipped outside State of Qatar and proof of shipping documents to be submitted to KAHRAMAA.

1.7.8 KAHRAMAA reserves the right to witness all types of testing locally, and the tests shall be carried out in accordance with applicable standards and codes.

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1.8 PACKING

1.8.1 The material/item shall be packed in compliances with KM and Manufacturer recommendation and procedure.

1.8.2 At Site, (from the pre-Inspection arrangement) all items shall be packed individually and put into the wooden box, which shall be close and open type. Every layer in wooden box shall be clamped properly to avoid abrasion during transit and damage to coating.

1.8.3 The cutting of pipes shall be kept to a minimum and after cutting the remaining length of calibrated pipes shall be suitably marked and re-stacked together with the remaining calibrated pipes.

1.9 TECHNICAL CLARIFICATION

1.9.1 In case there are disputes, KAHRAMAA shall have the right to ask the manufacturer all the technical documents that will help out in clarifying this dispute.

1.10 SAMPLES

1.10.1 Samples shall be provided when required by the engineer or instructed by the project documentation. Materials subsequently supplied shall conform to the quality

of the samples which have been approved by the engineer.

1.10.2 Each sample shall bear a securel y fixed label bearing the following information: I. Project Identification.

II. Contractor Identification.

III. Sample Identification including all information as to Manufacturer, Model Number, and Catalogue Number.

1.10.3 Materials subsequently supplied shall conform to the quality of the samples which have been approved by the engineer.

1.11 ALTERNATIVE MATERIALS

1.11.1 The Contractor may propose the use of alternatives to materials specified in the Project Documentation, Due to some problems or delay with the Manufacturer / Supplier, Such proposals shall be complete with all supporting information showing that the alternative Materials are complying with KAHRAMAA latest specification.

1.11.2 The use of alternative materials shall only be permitted if it is approved in writing by the Engineer.

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Section - 2

Ductile Iron Pipes and Fittings

2.1 GENERAL

These Clauses Shall Be Read In Continuation Of Section 1 Of This Specification . 2.1.1 All pipes and fittings shall be manufactured from approved grade of ductile iron. 2.1.2 All manufacture and testing shall be in accordance with the latest edition of

BSEN-545/ISO 2531, 4179, 8179 including any subsequent amendments and as specified below.

2.2 JOINTS

2.2.1 Spigot & socket pipes & fittings joints shall be provided with approved integrally cast ‘push-in’ type joints, each joint being supplied with an approved jointing - ring designed by the manufacturer solely for the purpose of sealing the joint.

2.2.2 All flanged pipes & fittings shall be provided with integrally cast/ or rotatable flanges drilled to BS EN 1092-2, PN16.

2.2.3 All flanged pipes, fittings and valves shall be supplied with approved EPDM multilayer cotton reinforced rubber gasket; which in comply with the requirement of BS6920 and shall be kept in a sealed sun proof bag with written information of the same.

2.2.4 The manufacture specification of all-joint details, gaskets and jointing rings shall be supplied to the Engineer by the Tenderer / Contractor for approval.

2.2.5 All jointing materials shall comply with Clause 1.1.1 of this specification. 2.3 LENGTH OF PIPES

2.3.1 All pipes shall be supplied in the lengths of 5.50/6.00 meters or as per project requirement.

2.4 MARKING

2.4.1 All pipes & fittings shall be marked in accordance with the latest edition of BSEN-545/ISO-2531.

2.4.2 Additional marking on the pipes and fittings must be included such as;  Tender Number

 Contractor's Name  Manufacturer's Name  Year of manufacture  Standard

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2.5 CERTIFICATE OFTEST

2.5.1 The Tenderer / Contractor shall provide signed certificates stating the results of all tests as specified in BSEN 545 / ISO 2531, 4179, 8179 and BS 3416.

2.5.2 KAHRAMAA reserves the right to witness tensile tests on bar test pieces selected on the basis of not more than one test piece for every batch of 100 pipes.

2.5.3 Where specified tests are to be witnessed, the tests shall be carried in accordance with the manufacturer’s quality control procedure of the relevant international standard.

2.6 EXTERNAL & INTERNAL COATING OF DUCTILE IRON PIPES & FITTINGS DURING

MANUFACTORY

2.6.1 All materials shall conform and meet all the requirements of the latest edition of BSEN545/ISO2531, ISO4179, ISO8179, BS3416 and BS6920.

2.6.2 All ductile iron pipes and fittings shall be internally lined by centrifugal method with Sulphate Resistance Cement (SRC) mortar lining as per requirement of the latest edition of BSEN 545 or ISO 4179 or epoxy coating.

2.6.3 D.I. Pipes and Fittings shall be cured in curing chambers.

2.6.4 For D.I. Fittings coated with epoxy externally/internally, it shall be conformed one of the following method;

 Fusion bonded epoxy coating shall be minimum thickness 300 micron (Polymeric anticorrosion) coating as per WIS No. 4-52-01.

 Electrostatic ally applied epoxy coating shall be minimum thickness 300 micron.  Fluidized bed epoxy coating shall be minimum thickness 300 micron.

 The color of coating shall be “Blue”, Code RAL-5000/5001/5005/5010/5017 or Black.

2.6.5 The external coating shall be of metallic Zinc coating of 130 gm/m2 on pipes and Zinc rich paint coating of 150 gm/m2 on D.I. Fittings as per the latest edition of BSEN 545 or ISO 8179.

2.6.6 The external finishing layer to all pipes & fittings after the application of the Zinc coating shall be of bitumen coating as per the latest edition of BS3416, Type 2.

2.6.7 The internal cement lining shall be uniformed and smooth as possible and shall be within the tolerance limit acceptable by the International standards.

2.6.8 The thickness of internal cement lining in D.I. Pipes & Fittings shall be as follows in accordance with the latest edition of BSEN 545 as follows (See table

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Nominal Size Thickness

80-300mmØ 4.0mm

350-600mmØ 5.0mm

700-1200mmØ 6.0mm

1400-2000mmØ 9.0mm

2.6.9 The contractor is to supply confirmation from manufacturer that cement lining to be used is suitable for use with the range of chemical characteristics of water detailed in Appendix “I.”

2.6.10 The internal section of sockets of pipes and fittings shall be painted with a minimum 100-micron thick epoxy coating. The coating shall be suitable for use in contact with potable water at +50 C.

2.7 FACTORYAPPLIEDPOLYETHYLENEEXTERNALCOATING

2.7.1 The factory applied polyethylene external coating shall be applied by extrusion or any other approved method as per BSEN 14628-2005 (Ductile iron pipes, fittings and accessories External polyethylene coating for pipes Requirements and test methods).

2.7.2 The factory applied polyethylene external coating shall be type PE-D pipe zinc-coated with minimum thicknesses accordance with latest edition of BSEN 14628-2005 as follows (See table

02):-Table (02) MINIMUMCOATINGTHICKNESSES

Nominal Size Thickness

80-250mmØ 2.50mm

300-450mmØ 3.0mm

500-1200mmØ 3.50mm

1400-2000mmØ 4.0mm

2.7.3 The color code of polyethylene external coating shall be Blue color RAL-5000/5001/5005/5010/5017.

2.8 PROTECTION OFABOVEGROUND& INSIDE CHAMBERSD.I. PIPES& FITTINGS

2.8.1 External coating of ductile iron pipes & fittings to be laid above ground or inside chambers shall be coated with zinc primer as per ISO 8179, and then followed by an application of bituminous finish coating. Bituminous finish coating shall contain aluminum of not less than 20% in the dry film and shall be in silver.

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2.8.2 The internal section of sockets of pipes and fittings shall be painted with a minimum 100-micron thick epoxy coating. The coating shall be suitable for use in contact with potable water at +50 C.

2.9 SPECIAL PROTECTION OFD.I. PIPES& FITTINGS

2.9.1 External coating of ductile iron pipes & fittings to be laid on location of high water table shall be coated with Polyurethane/Epoxy coating with minimum thickness of 300 microns.

2.9.2 External coating of ductile iron pipes & fittings to be laid on location of high water table shall be coated with Polyurethane/Epoxy coating with minimum thickness of 300 microns.

2.9.3 Ductile iron pipes and fittings which are completely immersed in water (i.e. piping inside reservoir) shall be coated with a minimum 300microns thickness fusion bonded epoxy.

2.10 PIPECUTTING

2.10.1 Unless specified otherwise the Contractor shall supply a minimum of 2% of pipes of each diameter gauged (calibrated) along two third of the pipe entire length starting from the spigot end. These pipes shall be clearly marked by the factory and stored separately in the Contractor's store yard.

2.10.2 Where it is necessary to cut pipes, the cutting shall be neatly and accurately performed by machine so as to leave the pipe end a true circle and normal to the pipe axis and the cut ends shall be chamfered and painted as per manufacturer's recommendations for damaged coatings and generally to the original coating (Zinc & Primer / Epoxy) of the D.I. pipes and fittings.

2.11 PACKING

2.11.1 Pipes of small diameters shall be packed in bundles. Every pipe shall be separated from each other with the help of properly designed wooden spacers. The bundle shall be secured firmly with proper straps and well faced wooden base supports for proper transport, handling and storage. Every bundle shall have only one length of pipe.

2.11.2 For big diameters, it should be supplied separately.

2.11.3 All pipes and fittings shall be supplied with plastic end caps & shall be maintain in good condition until the pipe is ready to be installed in the trench.

2.11.4 The packing shall be as per Section 1, Clause 1.8 of this specification.

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Section - 3

Slip-On Coupling and Flange Adaptors and Dismantling Joints and

Step Couplings

3.1 GENERAL

These clauses shall be read in continuation of Section 1 of this Specification. 3.2 SLIP-ON COUPLINGS

3.2.1 Slip-on couplings shall be manufactured from either cast iron or rolled steel and shall be suitable for use with ductile iron pipes to BSEN 545 / ISO 2531.

3.2.2 Couplings shall be similar in design to that detailed in BS-8010, Section 2.1, and ‘Slip-on Couplings’.

3.2.3 For New Potable Water Network Construction, Couplings are recommended up to 300mm Ø only, 400mm Ø and above, a mechanical Collar is to be used.

3.3 MECHANICALCOLLAR ’S

3.3.1 Mechanical Collars shall be manufactured from Ductile Iron and shall be suitable for use with ductile iron pipes to BSEN 545 / ISO 2531.

3.3.2 Mechanical Collars shall be suitable for normal pressure test up to PN-16. 3.4 FLANGE ADAPTERS

3.4.1 Flange adapters shall be manufactured from either cast iron or rolled steel and shall be suitable for use with ductile iron pipes to BSEN 545 / ISO 2531.

3.4.2 Flange adapters shall be suitable for jointing the flanges to PN-16, as detailed in BSEN 545 / ISO 2531.

3.4.3 Flange adapters shall be similar in design to that detailed in BS-8010, Section 2.1, ‘Flange adapters’.

3.5 DISMANTLINGJOINTS

3.5.1 Dismantling Joints shall be suitable for jointing the flanges to PN-16, as detailed in BSEN 545 / ISO 2531.

3.5.2 Dismantling Joints shall be similar in design to that detailed in BS-8010, Section 2.1, ‘Flange adapters’.

3.6 STEP COUPLINGS

3.6.1 Step couplings shall be manufactured from either cast iron or rolled steel and shall be suitable to joint between two pipes of different materials.

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3.7 EXTERNAL AND INTERNAL COATING OF SLIP-ON COUPLINGS, STEP COUPLINGS,

FLANGEADAPTERSANDDISMANTLINGJOINTSDURINGMANUFACTURE

3.7.1 All Slip-on couplings, step couplings, flange adapters and dismantling joints shall be coated both, internally and externally as per one of the following methods;

 Fusion bonded epoxy coating shall be minimum thickness 300 micron (Polymeric anticorrosion) coating as per WIS No. 4-52-01.

 Electrostatic ally applied epoxy coating shall be minimum t hickness 300 micron.  Fluidized bed epoxy coating shall be minimum thickness 300 micron.

 The color of coating shall be “Blue”, Code RAL-5000/5001/5005/5010/5017 or Black.

3.8 FASTENERS

3.8.1 All nuts and bolts must be made of Stainless Steel Grade “A4” or Grade 316L. 3.9 IDENTIFICATIONMETALSTRIP

3.9.1 All couplings and flange adapters shall be marked by engraving or embossing on a metal strip, the name of manufacturer, individual serial number, tender number and Year of manufacturing.

3.10 PACKING

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Section - 4

Corrosion Protection of Ductile Iron Pipes, Fittings & Accessories

4.1 PIPEWRAPPINGTAPE

4.1.1 The tape shall be supplied with width of 150 mm and 225 mm and with length 25 m, 30 m and 75 m per rolls.

4.1.2 Pipe diameters up to 200mmØ, 150mm width tape shall be used. 4.1.3 Pipe diameters 300mmØ and above, 225mm width tape shall be used.

4.1.4 For all types of fitting with diameters 100mmØ and above, 150mm width tape shall be used.

4.1.5 For normal application, high water table (Sabkha), high resistivity and contaminated areas, the self adhesive wrapping tape shall be applied with a 55% overlap shall be applied and sufficient tension in accordance with manufacturer instructions to ensure complete conformability and smoothed out as application proceeds to avoid air pockets.

4.1.6 Prior to backfilling the wrapped Pipes / joints shall be holiday tested, and the porosity shall be “zero” on 3 kV DC tester.

4.1.7 Wrapped pipes shall not be permitted to lie down on the ground except when finally positioned in the trench.

4.1.8 Wrapping tape dimension selection is Subject to Tenderer / Contractor Specification. 4.1.9 The adhesive compound shall be of the pressure sensitive type (that is, not requiring a primer in order to achieve bond to the substrata) and shall have thickness between 0.75 to 0.90mm.

4.1.10 The tape shall be supplied with a wider high quality silicon release paper covering complete tape and both sides of the tape shall have a minimum of 5mm wider silicon release paper to prevent edge contamination.

4.1.11 In case during storage at maximum storage temperature of 50 C for six months, the adhesive material shall not flow out of the release paper and there shall not be any end blocking.

4.1.12 Wrapping tape shall be marking in middle with the following information;  Manufacturers name & logo.

 Date of manufacture  Width of the tape  Batch Number

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4.2 WRAPPINGPROCEDURE

4.2.1 To increase the wrapping protection efficiency, pipe diameters up to 300mm must be wrapped using semi-Automatic Tape Wrapping Machine and for pipe diameters above 300mm, Fully Automatic Wrapping Machine should be used.

4.3 STORAGE

4.3.1 Wrapping tape shall be stored in dry, cool, well ventilated condition, the temperature of the store shall not exceed 30° C and out of direct sunlight.

4.4 PACKING

4.4.1 Roll shall be placed in a cardboard carton in layers in vertical position. A proper separator for safe storage shall separate each layer. The boxes shall be marked minimum at two places given name and logo of manufacturer, Tender No/ Title, Type, Size and quantity of material in black/blue color letters with a minimum height of 50mm.

4.5 WRAPPINGTAPEPROPERTY

4.5.1 The wrapping tape shall be conforming to the following specifications given in Table 03.

Table (03) WRAPPINGTAPEPROPERTYDATASHEET

SR. No.

Property Test Method Unit Data

A. Physical 1 Color

1.1 Backing --- --- Blue RAL

5000/5001/5005/ 5010/5017

1.2 Adhesive Compound --- --- Black

1.3 Release Paper --- --- White/Cream

2 Backing Type --- --- PVC

3 Backing Thickness Min. --- mm 0.75

4 Adhesive Thickness Min. --- mm 0.75

5 Total Thickness Min. --- mm 1.5

6 Elongation BS 2782 % 270

7 Tensile Strength Tape BS 2782 N/mm2 14.8

8 Modulus BS 2782 N/mm2 50

9 Tear Strength ASTM D1004 N 50

10 Impact Resistance (Two layers)

DIN 30627 Nm 15

11 Flow coefficient of Bitumen

11.1 Viscosity at 200º C Cone & Plate Poise 5.5 11.2 Viscosity at 175º C Cone & Plate Poise 7.5 12 Adhesion to Steel ASTM D 1000 N/mm 2.75 13 Adhesion to Tape ASTM D 1000 N/mm 2.75

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B. Electrical

13 Dielectric Strength BS 2782 kV 30

14 Insulation resistance ASTM D 257 Ohm/cm2 1012 15 Cathodic disbandment ASTM G 8 mm2 NIL C. General

16 Water vapor permeability BS 2782 g/m2/24h 0.4

17 Water absorption ASTM D 570 % 0.1

18 Bacterial growth disbandment --- --- NIL D. Temperature Range 19 For wrapping --- º C 0 to + 50 20 In service --- º C 0 to + 50 21 For storage --- º C up to + 30 4.6 PRIMER

4.6.1 The primer shall be of fast drying type. It’s only purpose shall be to maintain the surface cleanliness condition of the cleaned prepared D.I. pipe surface prior to tape application.

4.6.2 The primer shall be supplied in 20 to 25 Liters drums with following specifications given in Table 04.

Table (04) PRIMERDATASHEET

Property Data

Flash Point, C º 24 - 34

Weight Solid, % 58

Viscosity, CP 200 - 500

Coverage m2/l 6 - 12

Type Bitumen solution

4.7 PACKING

4.7.1 Drums shall be put into a wooden box, which shall be close and open type. The boxes shall be marked minimum at two places given name and logo of manufacturer,

Tender No. or Title, Type, Size and quantity of material in black or blue color letters with a minimum height of 50mm.

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4.8 WRAPPINGTAPEVISCOELASTICPOLYISOBUTENE

4.8.1 The specification of visco elastic wrapping tape shall be according to ISO 21809-3 Amendment 1 for Non crystalline Poly Iso Butene tapes.

4.8.2 The tape shall be supplied with width of 100 mm and 200 mm and with length 10 m, 20 m or approved by Engineer depending upon the r equirements.

4.8.3 Pipe diameters up to 200mmØ, 100mm width tape shall be used. 4.8.4 Pipe diameters 200mmØ and above, 200mm width tape shall be used.

4.8.5 For all types of fitting with diameters 100mmØ and above, 100mm width tape shall be used.

4.8.6 The wrapping tape shall consist of a polyolefin based corrosion preventing compound and a PE backing.

4.8.7 The corrosion preventing compound shall be a non-crosslinked, non-crystalline, low-viscosity polyolefin (that is, not requiring a primer in order to achieve bond to the substrate) and shall have thickness between 0.90 to 1.00 mm.

4.8.8 The tape shall be supplied with a high quality silicon release foil covering complete tape.

4.8.9 During storage at maximum storage temperature of +50° C, the adhesive material shall not flow out of the release foil and there shall not be any end blocking.

4.8.10 Wrapping tape shall be marking in middle with the following information;  Manufacturers name & logo.

 Date of manufacture.  Width of the tape.  Batch Number. 4.9 WRAPPINGPROCEDURE

4.9.1 Tools & Equipment required Temperature probe, Dew point tester, High voltage holiday tester.

4.9.2 The substrate should be free from condensing water which can be reached by keeping the temperature at least 3°C above dew point. The substrate should be dry, clean and protected against negative weather influences.

4.9.3 The area to be coated has to be clean, dry, and free from oil, grease and dust. All contamination including mill-scale has to be removed. De-gloss and degrease the surfaces by using an abrasive pad and isopropyl alcohol and e.g. a lint-free cloth.

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4.9.4 Minimum requirement for surface preparation is St 2 according to ISO 8501-1. Roughness profile should not be essential for adhesion.

4.9.5 Start wrapping with removal of a small part of the release liner and apply on the substrate without exerting any tension. Avoid air inclusions. Mould the tape tight onto the substrate surfaces.

4.9.6 Release foil should be removed only just prior to application onto the surface.  Overlap of wraps Side-by-side overlap: > 10 mm

 Consecutive rolls: = 50 mm

 Overlap on Existing coating= 50 mm.

4.9.7 The appearance of the tape must look smooth and tight and should be shaped around all details and into corners.

4.9.8 Holiday testing should be carried out immediately after application of wrapping tapes with a voltage of 15 kV. A brush probe is recommended. No further testing is required.

4.9.9 The wrapped pipe should not be exposed to loads e.g. from supports- or lifting equipment.

4.9.10 To increase the wrapping protection efficiency, pipe diameters up to 300mm must be wrapped using semi-Automatic Tape Wrapping Machine and for pipe diameters above 300mm, Fully Automatic Wrapping Machine should be used, manual wrapping is also acceptable.

4.9.11 Pipelines: Machine wrapped or manually wrapped protective coating on buried ductile iron pipelines. Field joints, Flanges, Couplings bell and spigot joint manually wrapped.

4.9.12 If the wrapping on the pipe is damaged during transportation localized repair should be performed as per above procedure.

4.9.13 If required extra mechanical impact resistance for Field Joints,Flanges & couplings can be achieved by applying an extra self-adhesive PE or PVC film on top of the tape wrap material. This will not be considered as extra corrosion prevention.

4.9.14 The self-adhesive PE or PVC film shall be applied with 50% overlap. 4.10 STORAGE

4.10.1 Store indoor, clean and dry, away from direct sunlight in a cool place below +50°C. Material should have Unlimited shelf life.

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4.11 PACKING

4.11.1 Roll shall be placed in a cardboard carton in layers in vertical position. A proper separator for safe storage shall separate each layer. The boxes shall be marked minimum at two places given name and logo of manufacturer, Tender No., Type, Size and quantity of material in black/blue color letters with a minimum height of 50mm.

4.12 WRAPPINGTAPE PROPERTY

4.12.1 The wrapping tape shall also conform to the minimum requirement given which is based on ISO 21809-3 Amendment 1(2011) and EN 12068 and shall be conforming

to the following specifications given in Table 05.

Table (05) WRAPPINGTAPEPROPERTYDATASHEET

Property Test

Temp.

Unit Requirements Test Method

Minimum thickness 23 °C mm 1.5 mm Annex A

Glass transition temperature - °C

< Minimum application temp minus 20 Annex E Holiday detection at 5 kV/mm + 5 kV - - No holiday Annex B Drip resistance Tmax+ - 15 °C

No drip at 80 °C Annex J Specific electrical insulation resistance - R S100 23 °C Ω.m² ≥ 108 Annex K -R S100/R S70 a ≥ 0,8

Peel strength test and

adhesion test with respect to steel and to plant coating before and after thermal

ageing resistance and before and after hot water

immersion test, both for 100 days at T + 20 °C (if reinforcement in the compound tape) 23 °C N/mm ≥ 0.2 _Cohesive failure Coverage ≥ 95 % The coating shall leave a film of corrosion protective coating material on the substrate. There shall be no evidence of adhesive failure Annex D 18.5.9.2 (and N.3 and Annex I) Tmax ≥ 0.2

Impact resistance (Single layer)

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Indentation resistance, Pressure 23 °C and Tmax N/mm² 1 EN 12068 ANNEX G Holiday detection at 5 kV/mm + 5 kV -Cathode disbandment resistance at 28 days 23 °C and Tmax mm 0 mm, no holiday Self-Healing* Annex F (and Annex B) Lap Shear Test 23 °C N/mm2 ≥ 0.02 cohesive failure Annex L Peel strength (layer-to-layer)

before and after thermal ageing resistance and before and after hot water

immersion test both for 100 days at Tmax + 20 °C.

23 °C N/mm ≥ 0.20 Annex M

UV Resistance 23 °C gJ/m2 17,5 EN12068

Lap Shear Test 23 °C N/mm2 ≥ 0.02 cohesive failure Annex L Peel strength (layer-to-layer)

before and after thermal ageing resistance and before and after hot water

immersion test both for 100 days at Tmax + 20 °C.

23 °C N/mm ≥ 0.20 Annex M

UV Resistance 23 °C gJ/m2 17,5 EN12068

MIC Resistance 23 °C - pass EN12068

Water absorption 23 °C % < 0.02 ASTMD5

70 Water vapour permeability 23 °C g/m2/day <0.2 ASTM

E96 Temperature for wrapping - °C - 20°C to +70°C -Temperature In service - °C -45°C to +70°C

-Temperature for storage - °C up to +50°C

-*Extra mechanical Outer wrap applied. 4.13 POLYETHYLENE SLEEVING

4.13.1 The polyethylene sleeving shall be manufactured to ISO 8180 and shall have the following additional characteristics:

-4.13.2 The film shall be manufactured in tubular form in blue color (RAL-5000/5001/5005/5010/5017) with a nominal thickness of the film shall be 225 microns with tolerance of  25 microns.

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4.13.3 The film shall be manufactured from polyethylene or a blend of polyethylene and/or copolymer of ethylene and higher olefins.

4.13.4 The film shall have UV absorber and UV

stabilizer-4.13.5 No recycled materials shall be used in the manufacture of the sleeving.

4.13.6 The test method of Polyethylene sleeving shall be as pre specifications given in Table 06.

Table (06) TESTMETHOD FORPOLYETHYLENESLEEVING

Property Data

Density Between 910-930 Kg/m3 tested as per ISO/R1183. Flow Index Less than 2.5g/600s tested as per ISO/1133

Tensile Strength Both directions not less than 8.3 MPa Elongation at Fracture: Not less than 300%.

4.14 MARKING

4.14.1 Polyethylene sleeving shall be supplied with a center guideline printed on the middle of the tape and the markings shall be consist the following;

 KAHRAMAA logo

 Manufacturers name & logo  Date of manufacturing )MM/YY(  Width & thickness of the sleeving  Size of the Relevant DI pipe in mm.

4.14.2 Lay flat width of PE sleeving for D.I. pipe shall be as given in Table 07. Table (07) DETAILS OFFLAT WIDTH OFPE SLEEVING

Sr. No. Nominal Ø of D.I. Pipe in mm Lay flat width in mm

1 80 280 2 100 320 3 150 435 4 200 540 5 300 755 6 400 980 7 450* 1090 8 500* 1215 9 600 1440 10 700* 1610 11 800* 1825 12 900 2025 13 1,000* 2255 14 1,200 2500 15 1,400 2800 16 1,600 3100

Note: * The subject Diameter’s are not be used in a new potable water network construction.

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4.15 PACKING

4.15.1 Each roll shall be individually packed and protected with shrinkable plastic sheet and marked with name and logo of manufacturer, Tender No/Title., Type, Size and quantity of material in black/blue color letters with a minimum height of 50mm. 4.15.2 The packing shall be as per Section 1, Clause 1.8 of this specification.

4.16 PVCBLACK SELF ADHESIVE TAPE

4.16.1 PVC black self adhesive tape shall be 50 mm/2” wide of length 30 meter/100 ft. in Rolls black in color. The tape shall be good quality and from an approved manufacturer.

4.16.2 The adhesive material shall be suitable when used in water and underground.

4.16.3 Each roll shall be individually packed and placed in a cardboard carton for safe storage.

4.17 JOINT MOLDING PUTTY

4.17.1 The joint molding putty used on all types of pipe joints shall be inert/non-toxic putty. 4.17.2 The putty shall be suitable for use with the approved PVC/Bituminous tape

wrapping materials. The putty shall be that recommended by the tape manufacturer. 4.17.3 The putty shall be supplied in 20-25 Kg drums or smaller packages as approved by

the Engineer.

4.17.4 Putty shall consist of the following properties as given in Table 08. Table (08) PUTTYCONSISTDATASHEET

Property Data

Color Black / Beige

Shrinkage: Nil

Temperature range Application: -10 to + 50 Cº Temperature range In service: -40 to + 75 Cº 4.18 PACKING

4.18.1 Drums shall be put into the wooden box, which shall be close and open type. The boxes shall be marked minimum at Two places given name and logo of

manufacturer, Tender No./Title, Type, Size and quantity of material in black/blue color letters with a minimum height of 50mm.

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4.19 STORAGE

4.19.1 Putty should be stored in original containers until required for use. Store in dry,

4.19.2 Cool, well ventilated condition, out of direct sunlight and other major sources of heat.

4.20 TRENCHMARKERTAPE

4.20.1 The tape shall be manufactured from non-biodegradable low-density virgin polyethylene in blue color (RAL-5000/5001/5005/5010/5017).

4.20.2 The tape shall be 150mm wide and 200 micron thickness with a tolerance of  5%. The rolls shall be of 500-meter long tape.

4.20.3 For PE Pipe and Road Crossing Duct, metallic blue Color a detectable warning tape of 150mm wide, 250microns thickness to detect the pipe through metal detector. 4.21 MARKING

4.21.1 The tape shall be inscribed with both Arabic and English in black color with a minimum height of letters 75 mm as follows:

FOR WATER MAINS – with the words

CAUTION: POTABLE WATER MAIN BELOW

---FOR SERVICE CONNECTIONS – with the words

CAUTION: POTABLE WATER SERVICE CONNECTION BELOW

---4.21.2 The trench marker tape shall be supplied with the following printed markings:

 KAHRAMAA logo

 Manufacturers name & logo  Date of manufacturing )MM/YY(  Width & thickness of the tape  Batch Number

4.22 PACKING

4.22.1 Each roll shall be individually packed and protected with shrinkable plastic sheet and marked with name and logo of manufacturer, Tender No/Title., Type, Size and quantity of material in black/blue color letters with a minimum height of 50mm. 4.22.2 The packing shall be as per Section 1, Clause 1.8 of this specification.

    

 

!



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---4.23 LUBRICANT

4.23.1 The lubricant shall be as per manufacturer’s recommendations and conforming to Section 1, Clause 1.1.1. of this specification.

4.24 PACKING

4.24.1 The lubricant shall be packed in 200 – 500 gram steel containers. These steel containers shall be placed in a cardboard carton for safe storage.

4.25 SLIP-ON COUPLINGS, FLANGE ADAPTERS AND DISMANTLING JOINT DURING

INSTALLATION

4.25.1 All wrapping tapes used for the corrosion protection of couplings and flange adapters shall be identical to that detailed in Section 4, Clause 4.1.

4.25.2 Moulding putty used for building up the contours on couplings and flange adapters, prior to the application of wrapping tape shall be identical to that detailed in Section

4, Clause 4.5.

4.25.3 All polyethylene sleeving used to cover couplings and flange adapters shall be identical to that detailed in Section 4, Clause 4.3.

4.25.4 All PVC Black adhesive tape shall be identical to that detailed in Section 4, Clause 4.26 HEATSHRINKSLEEVE

4.26.1 Heat shrink sleeve method for corrosion protection on pipes and fittings joints, coupling & flange adaptors during installation shall be applied, depends on Tender Requirements.

4.27 PACKING

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Section - 5

Bedding and Surround Material’s

5.1 GENERAL

These clauses shall be read in continuation of Section 1 of this Specification.

5.1.1 The pipes shall be laid in such a manner that the whole length of the pipe barrel is supported on the bedding material. At collars, sockets, flanges etc. the bedding material shall be removed to avoid point loads occurring at these locations. Bedding material shall be as per KAHRAMAA Specifications and shall be free from clay, large stones, rubbish, perishable matter or any other material which could damage the pipeline coating or assist in setting up corrosion, and the used material must be non-plastic material.

5.1.2 A samples will be taken from the accumulated piles at the approved source site and it will be tested on laboratory, if the result of the samples are compiling with KAHRAMAA specifications, The contractor is allowed to start having stock piles at the site and the contractor is allowed to start using the approved material (from the approved piles), and a randomly samples will be taken from the trench (preferably every 200.0 linear meters by the supervisors to assure the compliance of the delivered materials to the site.

5.2 IMPORTEDGRANULARMATERIAL ANDSELECTEDEXCAVATEDMATERIAL

5.2.1 Imported Granular Material shall comprise either of natural Dune Sand or Crushed Clean Hard Limestone or be a mixture of these.

5.2.2 Gabbros shall be used in water logged ground, (Sabkha), high resistivity, and contaminated areas.

5.2.3 The sand, crushed limestone or Gabbros shall be obtained from an approved source by the Engineer.

5.2.4 Granular material shall contain no excessive quantities of Dust, Soft or Flaky Particles, Shells congealed lumps, Nodules of soft clay, Shell, Alkali or other contaminated likely to affect adversely the compaction of the material or to cause damage to pipes.

5.2.5 The sulphate content (SO3) of the material shall not exceed 0.4% by weight and the Chlorides as (CI) shall not exceed 0.10 %by weight.

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5.2.6 The grading of fine aggregate when determined by the method described in BS 812 shall lie within the respective limits specified within the given Table 09.

5.2.7 The total quantity of fine dust through No. 22 mesh sieve in fine aggregate derived by crushing rock, shall be determined by the method described in BS 812 paragraph

14 and shall not exceed 8% by weight.

5.2.8 The total quantity of clay and silt in nature and shall not exceed 4% by weight when determined by the field setting test described in BS 812 paragraph 15.

Table (09) Normal Sand / Crushed Rock Percentage Passing by Weight B.S. Sieve Size (mm) Normal Sand Crushed Rock

4.76 95 – 100 90 – 100 2.40 70 – 95 60 – 90 1.20 45 – 85 40 – 80 0.60 25 – 60 20 – 50 0.30 05 – 30 05 – 30 0.15 0.0 - 10 0.0 - 15     

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Section - 6

Gate valves

6.1 GENERAL

These clauses shall be read in continuation of Section 1 of this Specification.

6.1.1 All gate valves shall be manufactured and tested in accordance with BS-5163 Type ‘B’/ BSEN 1171, BSEN 1074 and their amendments.

6.1.2 All gate valves shall be:

-A. Double flanged drilled according to BSEN 1092-2 PN16.

B. Face – to-face dimensions according to BSEN 558-1; Series 3 and 14. C. Designed for use with nominal pressure of 16 Bar.

D. With inside screw, solid wedge and shall be of non-ris ing stem type. E. Operated by the use of a removable key through a valve cap.

F. Suitable for use in a closed end test. 6.1.3 Gearbox shall be of:

 Standard ratio 1.1-10.1 (as specified)  Torque ranges 400-40,000 Nm.

 Thrust range 4,000-250,000 DaN

6.1.4 All gate valve and gear box shall be suitable for use with water temperature up to 50º C and in climate and soil conditions encountered in the State of Qata r.

6.1.5 All gate valves shall be of the resilient seat type.

6.1.6 All component parts of the valve body i.e. bonnet and stem seal housing shall be bolted together, where setscrews are used, the socket shall be provided with a PVC

cap.

6.1.7 All gate valves shall be designed for clockwise closing and be marked accordingly. 6.2 MOTORISEDACTUATOR

6.2.1 Electric type actuators shall include the motor, operators unit gearing, limit switches, torque switches, de clutch lever, auxiliary hand wheel, forward reversing and off position switches for local valve operation, local position indicator, local and remote selector switch, terminal for remote control, valve status and position indications(as specified below).

6.2.2 The actuator motor and all electrical enclosure shall be waterproof (IP67) as minimum. Motor shall be totally enclosed non ventilated construction with class F insulation with temperature rise limited to class B.

6.2.3 Actuator shall be suitable for operations in ambient temperature up to 50 degrees centigrade and capable of prolonged operations in a sand laden atmosphere. Available torque shall be at least two times the valve manufacturer's maximum

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torque requirements. The motor shall be designed specially for use on valve operation, having high torque capacity coupled with low inertia. Motor shall be of sufficient size to open or close a valve against the maximum specified differential pressure when the voltage drop at the motor is 10% of the nominal voltage.

6.2.4 Electrical power to the motor shall be 3 phase, 50 Hz, 415 V and motor rating shall be continuous duty. Heater and thermostats shall be provided for high humidity

condition.

6.2.5 The power gearing shall be consisting of helical gears of heat treated steel and worn gearing of hardened alloy steel. All power gearing shall be lubricated with high speed parts on anti friction bearing. It shall be possible to remove the motor/actuator from the valve without taking the valve out of service.

6.2.6 Provision shall be made for the incorporation of 4-20 mA position transmitters, powered internally to transmit the valve position remotely. The actuator shall be provided at least or minimum with following normally open/close dry contacts for

monitoring following status remotely:

Open, Close, Healthy/Available, Failed, In Remote and Local .

Also following provision to control actuator from remotely through NO/NC potential free contact.

Open & Close (In Desired Position), Stop 6.3 TESTING

6.3.1 The gate valve shall be tested as per BS 5163 as follows:

 Hydraulic test for body - 24 Bar  Hydraulic test for seat - 17.6 Bar

6.3.2 A factory test certificate shall be issued for each Gate valve giving its serial numbers, and the certificate shall be submitted to KAHRAMAA at the time of supply.

6.3.3 KAHRAMAA reserves the right to witness the testing of the valves locally. Testing shall be carried out in accordance with applicable codes and standards for the particular valves. Each valve shall be subjected to hydrostatic body and seat pressure test as mentioned in clause 6.3.1.

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6.4 HAND-WHEEL

6.4.1 Gate valves shall be supplied with cast iron hand wheels marked “Open” and “Closed” with arrow in appropriate directions. The design shall be such that it can be removed if necessary.

6.5 MARKING

6.5.1 All gate valves shall have clearly marked in the casting of the body the following information;

A. Size of valve in mm. B. Pressure rating in Bars.

C. Manufacturer’s name and/or logo. D. Material type (GGG40/GGG50/SG) E. Manufacturing Standards Number. F. Year of manufacture.

6.5.2 All gate valves shall have individual identification strip which shall be marked by engraving or embossing on a metal strip, the name of manufacturer, individual serial number, tender number and Year of manufacturing.

6.5.3 The metal strip shall be of minimum size of 100mm x 30mm and shall be fixed securely and permanently at appropriate location by industrial type cold welded glue and shall not be screwed or riveted. The glue shall be of industrial grade with a melting point higher than 80°C.

6.6 MATERIALS OFGATEVALVES

6.6.1 The valve body, bonnet, gland, yoke and wedge body shall be manufactured of ductile iron as per one of the following standard:

 DIN 1693 GGG-50/40

 BS EN 1563: 1997 grade EN-GJS-500-7  ISO 500-7, ISO 400-15

6.6.2 The stem shall be manufactured of acid resistance stainless steel 316L/BS 970 Gr 431 S29 with the threaded portion being formed by rolling process.

6.6.3 Stem nuts shall be gunmetal to BS 1400 LG2 or BS 2874 CZ132.

6.6.4 Dimensions and materials shall conform to those detailed in BS 5163, as applicable for Type “B”, and BS EN 1171.

6.6.5 The wedge body/core shall be manufactured from ductile iron.

6.6.6 The wedge shall be completely vulcanized by EPDM and coupled to the valve stem by gunmetal or dezincification resistance brass nut slide into the specifically

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designed slot hole in wedge or rigidly fastened into the wedge body by forging before rubber vulcanization.

6.6.7 Rubber material shall be of “EPDM EDK - 70” and the minimum thickness shall be 1.5 mm, and all sealing surfaces not less than 4.0 mm.

6.7 GEAR BOX

6.7.1 The properties of the gearbox shall be as given in Table 10. Table (10) Properties of the Gearbox Data Sheet

Property Data

Body & body cover Ductile Iron GGG 50/40, SG Bevel gear-shaft Steel / Carbon steel

Gear SG Iron, BS EN 1563 Grade 700-2, GGG 50 or AISI 1045

Bearing Steel

Plate & base plate Carbon steel

Stem nut Aluminum Bronze / Steel / DZR Brass 6.8 FLANGES

6.8.1 All gate valve flanges shall be drilled to suite ductile iron flanges as detailed in BS EN 1092-2, PN-16 rating.

6.8.2 Fasteners for joint shall be as per Section 1, Clause 1.6 of this specification. 6.9 GATE VALVE STEM SEALS

6.9.1 Gate valves up to and including 300 mm Ø shall have ‘O’ ring seals which are to comprise of seal, wiper rings and lip seal. There shall be a minimum of two wiper rings or one wiper ring and one lip seal in addition to the seal rings and shall be made of synthetic rubber material.

6.9.2 Gate valves above 300mm may have either ‘O’ ring seals, or stuffing boxes fitted with an approved ‘Teflon’ or graphite based packing material.

6.9.3 The stem sealing shall be maintenance free.

6.9.4 There shall not be any direct contact with spindle and bonnet to avoid cold welding. 6.10 MATERIALCOATING& INTERNALCOMPONENTS

6.10.1 The entire body of gate valves shall be coated both internally and externally with either of the following:

 300 micron Fusion bonded epoxy (Polymeric anticorrosion) coating as per WIS

No. 4-52-01.

 300 micron Electrostatic ally applied epoxy coating.  300 micron Fluidized bed epoxy coating.

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6.10.2 The color of coating shall be “Blue”, Code RAL-5000/5001/5005/5010/5017.

6.10.3 All materials coating shall be WRC, DVGW, SGS, and DWI. , KIWA, NSF 61 or other Worldwide Known Quality Body Certifiers in contact with potable water at +50 degrees centigrade.

6.10.4 The concern Department / Section has the right to request any Worldwide Known Quality Body Certifier if require.

6.10.5 All casting shall be properly finished, sand blasted and cleaned before coating. 6.10.6 Coating shall be smooth and mirror finish without any hairline cracks.

6.10.7 Adhesion Test: Adhesion of coating to metal shall not be less than 12N/mm2 (BSI BS EN ISO 4624).

6.10.8 Holiday Test: Porosity of coating shall be “zero” on 3 kV DC tester . 6.10.9 Hardness: Intrinsic Rockwell hardness shall be between 50 - 60.

6.10.10 Impact resistance: For applying of impact energy of 5 NM on coating the cracks should not develop, when tested by 3 kV DC tester.

6.11 ACCESSORIES

6.11.1 Each valve shall be supplied with all accessories such

as:- Bolts, nuts, washers and 3 mm cotton reinforced rubber gasket for each flange.  Caps.

 The number of torque wrench with bit / flank socket shall be Supplied:

a) From 1 to 20 valves, 1 torque wrench and bit / flank socket should be supplied.

b) For 20 valves and above 20% of the supplied quantity of torque wrench and bit / flank socket should be supplied.

 For the reservoir (RPS) the number of hand wheel shall be Supplied:

a) From 1 to 20 valves, 1 hand wheel should be supplied.

b) For 20 valves and above 20% of the supplied quantity of hand wheel should be supplied.

 Extension Operating Spindle as per KAHRAMAA Standard Drawings, rod with

all accessories such as coupling, cap, Wall Bracket, etc.

6.11.2 Valve keys shall be of the heavy duty mild steel, lever type, shall be and to be capable of opening valves against their designed working pressure heads and shall be capable of producing enough torque to close the valve to a drop tight extent. 6.11.3 For gate valve the number of valve operating “T” keys shall be supplied:

o _{From 1 to 20 valves, 1 of operating “T” key should be supplied.}

o _{For 20 valves and above 20% of the supplied quantity of operating “T” key}

should be supplied. 6.12 PACKING

WP-P5-S1_19!8!15 General Specification of Main Laying Materials for Waterworks

WP- P5/ S1

WP- P5/ S1

General Specification of Main

General Specification of Main

Laying Materials For

Laying Materials For

Waterworks

Waterworks

Document Control

Document Control

Issue Record

Issue Record

Document Control

Document Control

Issue Record

Issue Record

Table of Contents

1. Purpose

4. Abbreviations & Terminology

General

Ductile Iron Pipes and Fittings

Slip-On Coupling and Flange Adaptors and Dismantling Joints and

Step Couplings

Corrosion Protection of Ductile Iron Pipes, Fittings & Accessories

    

 



Bedding and Surround Material’s

Gate valves